Chicago Electric 91780 User manual

Brand: Chicago Electric

Model: 91780

Type: User manual

This manual is also suitable for

5,500 LB. WINCH WITH5,500 LB. WINCH WITH

5,500 LB. WINCH WITH

ROLLER FAIRLEADROLLER FAIRLEAD

ROLLER FAIRLEAD

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Web site at http://www.harborfreight.com

2004 by Harbor Freight Tools

of this manual or any artwork contained herein may be reproduced in any shape

or form without the express written consent of Harbor Freight Tools.

For technical questions and replacement parts, please call 1-800-444-3353.

TO PREVENT SERIOUS INJURY,

READ AND UNDERSTAND ALL WARNINGS

AND INSTRUCTIONS BEFORE USE.

91780

SKU 91780 Page 2For technical questions, please call 1-800-444-3353.

Specifications

Save This Manual

You will need the manual for the safety warnings and precautions, assembly instructions,

operating and maintenance procedures, parts list and diagram. Keep your invoice with this

manual. Write the invoice number on the inside of the front cover. Keep the manual and

invoice in a safe and dry place for future reference.

General Safety Warnings and Precautions

WARNING: When using tool, basic safety precautions should always be followed to

reduce the risk of personal injury and damage to equipment.

Read all instructions before using this tool!

1. Keep work area clean. Cluttered areas invite injuries.

2. Observe work area conditions. Keep work area well lighted. Do not use electrically

powered tools in the presence of flammable gases or liquids.

3. Keep children away. Children must never be allowed in the work area. Do not let them

handle machines, tools, or extension cords.

4. Store idle equipment. When not in use, disconnect the Winch and keep children away

from it.

5. Use the right tool for the job. Do not attempt to force a small tool or attachment to do the

work of a larger industrial tool. There are certain applications for which this tool was

designed. It will do the job better and more safely at the rate for which it was intended. Do

not modify this tool and do not use this tool for a purpose for which it was not intended.

6. Dress properly. Do not wear loose clothing or jewelry as they can be caught in moving

parts. Protective, electrically nonconductive clothes and nonskid footwear are recom-

mended when working. Wear restrictive hair covering to contain long hair.

Maximum Line Pull 5,500 Lbs.

Motor 12V, 3.4 Hp Magnetic Motor

Drum Size 2.64” Dia. x 4.49”

Cable

” x 80 Feet

Winch Dimensions 17.7” x 6” x 6.8”

Weight 58 Lbs.

Mounting Pattern 6.5” x 4.5”

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REV 05/05

SKU 91780 Page 3For technical questions, please call 1-800-444-3353.

7. Do not overreach. Keep proper footing and balance at all times. Do not reach over or

across the Winch cable.

8. Maintain tools with care. Keep the Winch clean for better and safer performance. Fol-

low instructions for lubricating and changing accessories. Inspect cords and cables

periodically, and if damaged, have them repaired by an authorized technician.

9. Stay alert. Watch what you are doing, use common sense. Do not operate the Winch

when you are tired.

10. Check for damaged parts. Before using the Winch, any part that appears damaged

should be carefully checked to determine that it will operate properly and perform its

intended function. Check for alignment and binding of moving parts; any broken parts or

mounting fixtures; and any other condition that may affect proper operation. Any part that

is damaged should be properly repaired or replaced by a qualified technician. Do not

use the Winch if any switch does not turn On and Off properly.

11. Replacement parts and accessories. When this unit is serviced by a qualified techni-

cian, only identical replacement parts should be used. Use of any other parts will void

the warranty. Only use accessories intended for use with this tool. Approved accessories

are available from Harbor Freight Tools.

12. Do not operate Winch if under the influence of alcohol or drugs. Read warning

labels if taking prescription medicine to determine if your judgment or reflexes are im-

paired while taking drugs. If there is any doubt, do not operate the Winch.

13. Maintenance. For your safety, service and repairs should be performed regularly by a

qualified technician. This unit should receive regular maintenance.

14. Pacemaker safety warning. People with pacemakers should consult their physician(s)

before using this product. Electromagnetic fields in close proximity to a heart pace-

maker could cause interference to or failure of the pacemaker.

Note: Performance of this tool may vary depending on variations in battery power.

Specific Winch Warnings and Precautions

1. Keeps hands and body away from Fairlead (cable intake slot) and operating gears when

operating the Winch and when the Winch is supporting a load.

2. Secure vehicle in position with the emergency brake and wheel blocks before using

winch. Never keep the vehicle in Park or in gear while using the Winch.

3. Do not exceed winch Rated Line Pull Capacity (5,500 Lbs.).

4. Be certain winch is properly bolted to a structure (or vehicle) that can hold the Winch and

the load supported by the Winch.

5. Always use proper couplings when connecting winch cable hook to load.

6. Do not lift items vertically. The winch was designed for horizontal pulling use only.

7. Never leave the Winch unattended when it is under a load.

8. Do not use inappropriate attachments to extend the length of the winch cable.

SKU 91780 Page 4For technical questions, please call 1-800-444-3353.

Winch Warnings and Precautions (continued)

9. Never pull people or pull loads over people. Do not lift people or animals; as noted in

Specific Warning

6, this Winch should not be used for lifting whatsoever.

10. Never come in between the winch and the load when operating.

11. Examine Winch before using. Components may be affected by exposure to chemicals,

salts, and rust. Do not use the Winch if even minor structural cracks, bends, a frayed

cable, or any other condition that may affect safe operation are noted.

12. Do not apply winch to load when cable is fully extended. Never fully extend cable while

under load. Keep 4 complete turns of cable around the winch drum.

13. When loading a boat into a trailer without keel or side hull rollers, make sure the trailer is

submerged in the water (but not the Winch) when the boat is loaded by the winch.

Attempting to drag the boat on to the trailer while on land can cause winch failure and

possible injury.

14. Never operate winch if cable shows any signs of weakening, or is knotted or kinked.

15. Winch does not have a locking mechanism. After moving an item with the winch, secure

the item. Do not rely on the winch to hold it for an extended period.

16. Do not cross over or under cable under load.

17. Do not move vehicle with cable extended and attached to load to pull it. The cable could

snap.

18. Use leather gloves while handling cable. Always wear ANSI approved safety goggles

during setup, use, and maintenance.

19. Re-spool cable properly in a smooth pattern as shown in the photo on the next page.

20. Not to be used for aircraft purposes.

21. Make sure to read and understand all instructions and safety precautions as outlined in

the manufacturer’s manual for the object you will winch. Make sure you attach the Cable

Assembly (36) to the manufacturer’s recommended pulling point.

22. Make sure to read and understand all instructions and safety precautions as outlined in

the manufacturer’s manual for the vehicle/trailer to which the Winch will be attached.

23. Use extreme caution when applying or releasing a load. Never allow the load to sud-

denly release. Carefully and slowly, apply and release the load.

24. This Winch is designed for mounting on square or rectangular surfaces. Never attempt

to mount the Winch on a round surface.

25. Do not replace the Steel Cable with ropes or fiberglass straps. This Winch is only de-

signed to work with the 1/4” Steel Cable provided. Replacement cables for this winch

should only be ordered through Harbor Freight Tools as parts for this item.

Warning: The warnings, cautions, and instructions discussed in this instruction manual

cannot cover all possible conditions and situations that may occur. It must be under-

stood by the operator that common sense and caution are factors which cannot be

built into this product, but must be supplied by the operator.

SKU 91780 Page 5For technical questions, please call 1-800-444-3353.

Unpacking

When unpacking, check to make sure that all of the parts listed on pages 9, 11, and 12, are

included. If any parts are missing or broken, please call Harbor Freight Tools at the number

on the cover of this manual as soon as possible.

Switch Assy. (35)

Battery Wire Assembly (17 & 20)

Solenoid Unit

Cable Assembly (36)

Roller Fairlead

Assembly Hardware

FIGURE 1

Winch

Cables From

Solenoid (34w)

Cam Ring (11w)

REV 11/04; 0505

Roller Fairlead

Mounting Plate (46)

and

Hardware (43,44, & 45)

SKU 91780 Page 6For technical questions, please call 1-800-444-3353.

Installation

Warning! Injury or death can occur if this Winch comes apart from its mounting location

when it is under load. Electrical damage or fire may occur if the Winch is wired improp-

erly. For these reasons, it should only be installed by a qualified technician.

1. After matching up the mounting holes, attach the Roller

Fairlead (2w) to the Mounting Plate (46w) using the sup-

plied M12 Bolts (43w), Nuts (44w), and Washers (45w).

2. Now mount the Roller Fairlead and Mounting Plate as-

sembly to the mounting channel (not included) or other

suitable mounting point using the included hardware

(M10, bolt, lock washer, and nut). It is recommended

that the Harbor Freight Universal Mounting Channel

(SKU 90476) be used.

NOTE: If recommended mounting channel is not used, a

mounting channel or mounting point of equal or greater

design, must be used.

3. Now place the mounting channel in position on the ve-

hicle and mark on the vehicle’s frame where the holes

will need to be drilled for the winch’s mounting hardware. Remove the mounting chan-

nel from the vehicle and drill the holes for the mounting channel.

4. Attach the Winch to the mounting channel (not included) using Bolts (3w), Flat Washers

(5w), Lock Washers (4w), and Nuts (6w). NOTE: Tighten bolts to at least 35 ft. lbs. of

torque.

5. Connect the

short Solenoid Cables to the terminals on the Winch. The cables can be

connected to either terminal.

6. Mount the Solenoid (34w) to the mount-

ing channel (not included) using three

Lock Washers (4s) and three Nuts (3s).

The Solenoid may also be mounted to

the Winch motor using the included So-

lenoid mounting bracket (7s). Remove

both Bolts (12-1w) and Nuts (13w) from

the Motor End Bearing Ass’y (33w). Then

align the Solenoid Bracket (40w) with the

2 mounting holes. Attach the Solenoid

bracket to the Motor End Bearing Ass’y

(33w) by reattaching the Tie Bars (10w)

with the Bolts (12-1w) and Nuts (13w)

that were previously removed. Tighten. Secure the Solenoid Bracket (40w) to the Motor

End Bearing Ass’y (33w) by attaching the Bracket Tie Down Strap (41w) around both

the Solenoid Bracket and the Motor End Bearing Ass’y. Pull Strap until secure. Attach

the Solenoid to the bracket using the Lock Washers (4s) and Nuts (3s). See FIGURE 3.

7. Place the mounting channel and Winch on the vehicle. Now align the holes previously

drilled in the vehicle frame with the holes in the mounting channel. Using four each of

REV 11/04; 05/05

FIGURE 3

SKU 91780 Page 7For technical questions, please call 1-800-444-3353.

Operation

1. Disengage the clutch of the Winch by moving the Cam Ring (11w) to the out position.

See FIGURE 1.

2. Pull the Cable Assy. (36w) out the to the desired length, then attach the Hook to the item

being pulled. Make sure the Hook’s spring-loaded latch is set.

Warning: Always leave at least four turns of cable on the drum. Review Winch Safety

Warnings and Precautions on pages 3 and 4 before continuing.

3. Reengage the clutch by moving the Cam Ring (11w) to the in position.

See FIGURE 1.

4. Open the

Cover (Female Conn.) (12s) on the Solenoid (34w) unit. Insert the Switch Assembly

(35w) plug into the connector on the Solenoid (34w).

Note: The vehicle battery must be fully charged and the engine running before using

the Winch.

Caution: Avoid damaging the vehicle transmission. Do not have the transmission in

Park or in any gear. Set the Emergency Brake and place wheel chocks, then put in neu-

tral.

Installation (continued)

Bolt (3w), Flat Washer (5w), Lock Washer (4w) and Nut (6w), place through the mounting

channel and the vehicle frame and tighten to at least 35 ft. lbs.

NOTE: The winch should be mounted to flat part of the vehicle (frame) that is capable of sup-

porting and evenly distributing the Winch and its full load capacity. Remember, the Winch

is designed for horizontal pull, NOT vertical.

8. Connect the (two short Black) Solenoid Cables to both terminals on the Winch (see

FIGURE 1). Securely tighten nuts.

Caution: The Battery cables should not be drawn taut. Leave slack for some cable move-

ment. Do not route cables near moving engine parts, or heated areas that could melt the

cable insulation.

9. Connect the Battery Wire Assy. Red (positive +) (17s) from the Solenoid Assembly (34w)

to the positive (+) terminal on the vehicle’s 12 volt battery.

10. Connect the Battery Wire Assy. Black (negative –) (20s) from the Solenoid Assembly

(34w) to the negative (–) terminal on the vehicle’s 12 volt battery.

11. To check for correct winch motor rotation, first disengage the winch clutch by moving the

Cam Ring (11w) to the “out” position.

12. Pull out 3-4ft. of the Cable Assy. and then reengage the winch clutch by moving the Cam

Ring (11w) to the “in” position.

13. Insert the Switch Assy. (35w) into the Connector (9s) on the side of the of the Solenoid

Assy. (34w).

14. Now momentarily press the “Red” button on the Switch Assy. (35w) and observe if the

cable is being wound back into the winch. If not, first disconnect the Red (+) battery

cable and then reverse the two short Black Solenoid cables attached to the end of the

winch motor (see Figure 1). Now reconnect the battery cable. Installation of the winch is

now complete.

REV 11/04; 05/05

SKU 91780 Page 8For technical questions, please call 1-800-444-3353.

Maintenance

Lubrication

1. All moving parts within the Winch have been lubricated using high temperature lithium

grease at the factory. No internal lubrication is required.

2. Lubricate cable periodically using a light penetrating oil.

Cable Assembly Replacement

(To be performed only by a qualified service technician.)

1. Move Cam Ring (11w) to the OUT position.

2. Extend Cable Assy. (36w) to its full length. Note how the existing cable is connected to

the inside of the drum.

3. Remove old Cable Assembly and attach new one.

Caution: Do not replace with inferior cable. Always use the approved replacement part

from Harbor Freight Tools.

4. Retract Cable onto cable drum being careful not to allow kinking.

General

1. Keep vehicle battery in good condition.

2. Be sure that the Winch battery cables are not drawn tight against any surfaces which

could possibly damage them.

3. Periodically remove and clean cable connections to the battery fuse box and chassis

ground. Corrosion will reduce performance or may cause a short.

4. Cover the cables and Winch when not in use.

5. While standing aside of the tow path, press (and hold) the RED push-button on the Switch

Assy. (35w) to pull the load. If the load will not move, release pull switch and check for

obstacles blocking the load, or check to see if load is too heavy for Winch capacity.

Always wait until the motor has stopped before changing directions!

6. To reverse directions, press (and hold) the opposite push-button to release the load.

7. When the pulling is complete, secure the load so it cannot move in either direction.

Caution: The Winch is designed for intermittent use only, and should not be used in a

constant duty application. The duration of the pulling job should be kept as short as

possible. If the Winch motor becomes very hot to the touch, stop the Winch and let it

cool down for several minutes. Never pull for more than one minute at or near the rated

load. Do not maintain power to the Winch if the motor stalls as it can damage the motor

or gears.

SKU 91780 Page 9For technical questions, please call 1-800-444-3353.

NOTE: Some parts are listed and shown for illustration purposes only and are not available individually

as replacement parts.

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN

THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR

MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS

QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO RE-

PLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EX-

PRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY

CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK

AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACE-

MENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS

THERETO.

Winch Parts List

Note: When ordering parts for the Winch unit, always include the suffix “w” after the part number.

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REV 11/04; 05/05

SKU 91780 Page 10For technical questions, please call 1-800-444-3353.

Winch Assembly Drawing

NOTE: Some parts are listed and shown for illustration purposes only and are not available individually

as replacement parts.

Note: When ordering parts for the Winch unit, always include the suffix “w” after the part number.

REV 05/05

SKU 91780 Page 11For technical questions, please call 1-800-444-3353.

Part No. Description Qty. Part No. Description Qty.

1s Screw 7 14s Nut 6

2s Cable Bracket 3 15s Washer 4

3s Nut M6 6 16s Solenoid (12V) 2

4s Lock Washer D6 3 17s Battery Wire Assy. - Red, 60” 1

5s Spacer 3 18s Battery Wire Assy. - Blk., 6 Ga.x 3-1/2” L 1

6s Bolt 3 19s Copper Strap 1

7s Bracket 1 20s Wire Assy. - Battery Black 60” 1

8s Screw 2 21s Washer 5/16 Shake-proof External Teeth 1

9s Connector (Female) 1 22s Copper Strap 2

10s Solenoid Cover 1 23s Wire Assy. - Blk., 16 Ga.x 1-1/2” L 1

11s Lock Washer 2 24s Wire Assy. - Blk., 10 Ga.x 6” L 2

12s Cover (Female Conn.) 1 25s Wire Assy. - Blk., 6 Ga.x 3” L 1

1 3 s Te rminal Tab 4

NOTE: Some parts are listed and shown for illustration purposes only and are not available individually

as replacement parts.

Solenoid Parts List and Assembly Drawing

Note: When ordering parts for the Solenoid unit, always include the suffix “s” after the part number.

SKU 91780 Page 12For technical questions, please call 1-800-444-3353.

NOTE: Some parts are listed and shown for illustration purposes only and are not available individually

as replacement parts.

Roller Fairlead Specifications, Parts List, and Assembly Drawing

Note: When ordering parts for the Fairlead unit, always include the suffix “f” after the part number.

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REV 05/05

Chicago Electric 91780 User manual

Brand: Chicago Electric

Model: 91780

Type: User manual

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Chicago Electric 91780 User manual

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